Spikeless tie plate fasteners, pre-plated railroad ties and related assemblies and methods

ABSTRACT

Spikeless plated and pre-plated railroad ties, assemblies, railroad tracks and related methodology are disclosed wherein two-part fasteners are used in respect to sets of aligned tie and tie plate apertures such that the two fastener parts are joined together against inadvertent separation within each tie aperture at a connection or union site, which includes but is not limited to force fit unions and threaded unions.

FIELD OF INVENTION

The present invention relates generally to tie-supported railroad tracks and more particularly to spikeless tie plate fasteners, spikeless pre-plated railroad ties, related assemblies and methods.

BACKGROUND

In regard to railroad ties formed of wooden, plastic and composite materials, traditionally spikes are driven through apertures in two-spaced tie plates, placed on top of each tie, into non-apertured tie locations. The extent to which the spikes, once driven, are held in place depends on the compression forces of the tie material against each spike. If the spike loosens, the associated tie plate will also loosen, creating a potential for damage and a danger for trains traveling over the track. While the driven spike approach typically works well with soft wood and other soft materials, it often does not with hard woods and other hard materials. While hard wood ties last longer than soft wood ties, hard wood ties are too often split by the spikes as the spikes are driven. Thus, the split hard wood tie does not compressively hold the spikes in the fully driven position and the tie plates become loose creating the potential for damage and danger mentioned above.

Use of nut and bolt fasteners in lieu of spikes for hard wood ties has heretofore been rejected in the railroad industry because of the cost of pre-drilling the ties and difficulty in stacking such pre-plated ties in inventory and on transportation vehicles. Tightening of such bolts into associated nuts, to retain an associated tie plate tightly on the tie, has been problematic because the nut not only extends beyond the bottom of the tie, but often rotates as the bolt is rotated.

Screw spikes, which tend to cause the tie to split, have also been proposed for holding tie plates correctly on top of railroad ties, but the screw spikes tend to fracture, under the forces of train vibration over time, at the reduced diameter site located between the shank and the top of the threads.

Based on the prior art described above, it would be a major break through to provide effective spikeless tie plate fasteners reliable spikeless pre-plated hard wood railroad ties, and related assemblies and methods.

BRIEF SUMMARY AND OBJECTS OF THE INVENTION

In brief summary, the present invention overcomes or substantially alleviates problems of the past related to securing tie plates to railroad ties, especially, but not limited to, dense ties comprised, for example, of hard woods and other dense materials. More specifically, the present invention is directed to novel spikeless tie plate fasteners, spikeless pre-plated railroad ties, railroad tracks comprising such and related assemblies and methodology.

Dense railroad ties, frequently formed of hardwood, synthetic resin or composite material, are apertured top to bottom with an array of apertures forming a predetermined pattern matching a pattern of apertures in tie plates. With the tie apertures aligned with the tie plate apertures, a two-part fastener is used in respect to each set of aligned tie and tie plate aperture. The two fastener parts, in each case, are joined together against inadvertent separation within the associated tie aperture at a connection or union site, between the two fastener parts, which includes but is not limited to force-fit unions and threaded unions.

Typically, the two-part fasteners each comprise a first or top shaft fastener member inserted through aligned tie plate and tie apertures so that a proximal head thereof is contiguous with the top surface of the associate tie plate. A distal end portion of the first fastener member is disposed within the associated tie aperture and is not connected to the tie. The distal end portion, in the assembled state, is disposed above the bottom surface of the tie in the associated tie aperture. The other, lower or bottom fastener member is inserted from the bottom of the tie into the associate tie aperture, in non-rotatable relation. The other fastener member is preferably entirely disposed within the associate tie aperture (to better allow stacking of pre-plated railroad ties in inventory and on transportation vehicles) and is covered by a layer or seal for the purpose of protecting the other fastener member from corrosion infiltrating from the ballast.

With the foregoing in mind, it is a primary object of the present invention to overcome or substantially alleviate problems of the past related to securing tie plates to railroad ties.

Another paramount object is the provision of a novel system, unique assemblies and distinct methodology for building railroads, spikelessly pre-plating railroad ties and providing two-part fasteners for use in pre-formed apertures of railroad ties to secure tie plates in position, which features are especially effective with ties formed of hard dense material, such as hardwoods, high molecular weight plastics and dense composites.

Another important object is the provision of novel spikeless tie plate fasteners, spikeless pre-plated railroad ties, railroad tracks comprised of such, and related assemblies and methodology.

It is another dominate object of this invention to provide one or more of the following features in spikeless railroad tie plate fasteners, pre-plated apertured railroad ties, construction of railroad tracks and related assemblies and methodology:

-   -   1. Use of dense railroad ties, formed of hard wood or synthetic         resin or composite material, which are pre-apertured top to         bottom with an array of apertures forming a predetermined         pattern matching a pattern of apertures in tie plates to be         assembled on the ties;     -   2. Use of two-part spikeless fasteners placed in aligned tie and         tie plate apertures, with the fastener parts being joined         together against inadvertent separation within each tie aperture         at a connection or union site, which may include, but is not         limited, to force-fit unions and threaded unions;     -   3. Use of stepped bores or pre-formed apertures in railroad ties         to accommodate reception of two-part spikeless fasteners;     -   4. Use of two-part spikeless fasteners, each comprising a first         shaft fastener member inserted through aligned tie plate and         pre-formed tie apertures so that a proximate head of the first         fastener member becomes tightly contiguous with the top of the         associate tie plate and a distal end portion, when fully         assembled, is disposed within the associated tie aperture above         the bottom surface of the tie, without connection to the tie;     -   5. Use of first and second fastener components, where rotation         of the second spikeless fastener component is prevented because         it is inserted into the associate tie aperture from the bottom         of the tie, in non-rotatable relation;     -   6. Use, in conjunction with a first spikeless fastener member,         of a second spikeless fastener member, which is concealed within         the associate tie aperture to better allow stacking of         pre-plated railroad ties in inventory and on transportation         vehicles and to accommodate protection of the other fastener         member from corrosion;     -   7. Use of locking connectors between first and second fastener         members disposed in pre-formed apertures in railroad ties to         pre-plate the ties so that inadvertent separation of the         fastener members is prevented or greatly alleviated;     -   8. Sealing within a tie aperture of a recessed lower fastener         member of a two-part fastener to prevent or alleviate corrosion         and deterioration;     -   9. Use of a second fastener member within a tie aperture, where         the second fastener member comprises a top connector portion to         receive a connector of a first fastener member, and an         anti-rotate base portion;     -   10. Use of pre-formed stepped apertures in railroad ties to         accommodate reception of two-part fasteners;     -   11. Use of two-part fasteners in apertures of railroad ties, one         with an anti-rotate feature, to accommodate tightening and         loosening of the two-part fasteners from the top of the tie         only;

These and other objects and features of the present invention will be apparent from the following detailed description taken with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective of a two-part fastener in accordance with principles of the present invention.

FIG. 2 is a perspective of a second lower fastener member, which may be substituted for the lower fastener member FIG. 1;

FIG. 3 is a fragmentary perspective of a railroad tie having a tie plate mounted at the top surface thereof, using the two-part fasteners illustrated in FIG. 1.

FIG. 4 is an enlarged fragmentary cross-section taken along lines 4-4 of FIG. 3;

FIG. 5 is a bottom plan view taken along line 5-5 of FIG. 4;

FIG. 6 is a bottom plan view taken alone line 6-6 of FIG. 7;

FIG. 7 is an enlarged fragmentary cross-section, similar to FIG. 4, illustrating the railroad tie of plastic or composite material as opposed to hard wood;

FIG. 8 is a fragmentary elevation shown partly in cross-section depicting a two-part fastener which may be used in lieu of the two-part fastener of FIG. 1 and which is adapted to create a force fit union within a tie aperture between the two fastener parts;

FIG. 9 is a fragmentary elevation, with a part broken away for clarity, illustrating an additional two-part fastener in accordance with principles of the present invention; and

FIG. 10 is a diagrammatic representation of the manner in which railroad ties may be pre-plated and stored or transported, in accordance with principles of the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Reference is now made to the drawings wherein like numerals are used to designate like parts throughout. As mentioned above, when hard wood ties are used to build or renovate a railroad track, the traditional method of utilizing railroad spikes is often counterproductive because the spikes tend to split the hard wood so that the embedded end of the spikes are not held tightly in position and, therefore, loosen responsive to railroad vibrations as trains move along the track. This can and does create certain risks of damage and danger and increases the amount of maintenance attention required. The same difficulty tends to exist when other dense materials are used, such as high molecular weight synthetic resinous materials and dense composite materials. While the present invention is directed toward railroad ties made of dense material, the present invention works well with softer tie materials, such as soft woods.

Central to the present invention is to utilize preformed apertures in railroad ties into which novel two-part fasteners are placed. One such two-part fastener is illustrated in FIG. 1, to which reference is now made.

The two-part fastener of FIG. 1 is generally designated 20 and comprises first and second fastener members, generally designated 22 and 24, respectively. The two-part fastener 20 is adapted to be used in lieu of a railroad spike to resolve or alleviate the tie splitting problem mentioned above. The first or top fastener member 22 comprises a male or shaft fastener member comprising distal threads 26, a smooth shank 28 above the threads 26 and a proximal head, generally designated 30.

The head 30 comprises a diametrally enlarged flange 32, the diameter of which is substantially greater than the diameter of the shaft comprising shank 28 and threads 26 and substantially greater in diameter than the apertures preformed in the railroad ties, as explained hereinafter in greater detail. The head 30 also comprises an upwardly extending square-shaped four-sided projection by which the fastener member 22 is rotated using a conventional wrench or the like. The head 30 is adapted to be exposed above a tie plate, after the plate is placed on the top of a railroad tie, so that the enlarged annulus or flange 32 rests contiguously and forcibly upon the top surface of the associated tie plate, as explained herein in greater detail.

While any one of several materials may be utilized to form fastener member 22, currently, for cost and reliability purposes, a high grade steel is preferred.

With continued reference to FIG. 1, the second fastener member 24 comprises a boss 36 comprising a hollow interior defined by internal threads 38. The boss 36 is illustrated as being crimped or indented at site 40, which reduces the diameter of the internal threads 38 in a localized region. The boss 36 is formed as one piece or integrated with an anti-rotate eccentric base 42, illustrated as being planar or plate-like. When the second fastener member 24 is placed in a stepped aperture, from the bottom of a railroad tie, as illustrated in FIG. 4, the eccentric relationship between the center line of the boss 36 and the center line of the base 42, when positioned as illustrated in FIG. 4, prevents the fastener member 24 from rotating as the fastener member 22 is turned causing matching or mating threads 26 and 38 to become threadedly connected, with the crimp 40 preventing inadvertent reverse rotation of threads 26 in respect to threads 38. Thus, the insertion and, if necessary, removal of fastener 20 can be accomplished from above the tie.

Reference is now made to FIG. 2, which illustrates a second form of a lower fastener member, generally designated 24′, comprising the previously described boss 36, equipped with two opposed crimps or indentations 40 to prevent inadvertent reverse rotation or the top fastener member, as explained above. The boss 36 of FIG. 2 is formed as one piece or is integrated with a rectangular or square base 42′, which is flat or planar in its configuration and, when placed in a rectangular recess at the lower part of a vertical aperture in a railroad tie, as shown in FIG. 7, becomes an anti-rotate component preventing boss 24′ from turning as fastener 22 is threaded into threads 38 of the lower fastener member 24′.

When the two-part fastener of FIG. 1 or a two-part fastener comprising fastener member 22 FIG. 1 and fastener member 24′ of FIG. 2 are properly assembled with a tie plate and a pre-apertured railroad tie, the configuration illustrated in FIG. 3 results. In FIG. 3, the railroad tie is generally designated 44 and comprises a top surface 45 and a bottom surface 47. The tie plate, which is conventional, is generally designated 46. Tie plate 46 comprises a central flat region 48 upon which a railroad rail is placed and is conventionally secured, by structure not shown. Two tie plates are used at the top of each railroad tie, so located to accommodate two railroad ties having the proper gauge for the railroad track in question.

Reference is now made to FIG. 4, which illustrates fastener 20 in its full assembled position through a stepped aperture 50 preformed in a wooden railroad tie 44.

The aperture 50 is representative of the other four apertures associated with each tie plate and comprises a top uniform diameter portion 52, the diameter of which is just slightly greater than the diameter of the shank 28 of fastener member 22. The aperture 50 is enlarged at shoulder or step 54 to accommodate snug reception of the boss 36 of the fastener member 24. The aperture 50 is again enlarged eccentrically at shoulder 56 to provide a disc-shaped recess to accommodating anti-rotation reception of the base 42 of the fastener member 24. This relationship is illustrated in FIG. 5. Thus, when fastener 22 is rotated so that external threads 26 turn into or out of the internal threads 38, the eccentricity of the base 42 in respect to the boss 36 prevents fastener 24 from rotating.

The bottom surface of the base 42, in FIG. 4, is illustrated as being sealed by a layer or coating of protective material 60, which prevents corrosion and deterioration of the base 42 by reason of the tie 44 resting upon ballast, which comprises part of a railroad track.

FIG. 4 also illustrates the placement of a railroad rail, as part of a two rail track, on tie plate surface 48, held there by conventional structure, not shown.

Reference is now made to FIG. 7 which illustrates a railroad tie 44′ formed of synthetic resinous or composite material. The aperture 50 shown in FIG. 7 is identical to aperture 50 shown in FIG. 4, with one exception. In lieu of the eccentric enlargement or recess 56, a concentric rectangular recess 56′ is provided. This accommodates anti-rotate reception of the rectangular or square base 42′ (FIGS. 2 and 6) in recess 56′, thereby preventing rotation of fastener member 24′ as the thread 26 of fastener member 22 are turned into or out of threads 38. While tie 44′ may be of dense material, the present invention may be utilized with tie materials which are softer than dense hard wood, composite and synthetic resinous materials.

Reference is now made to FIG. 8 which illustrates an additional two-part fastener embodiment in accordance with the principles of the present invention. The two-part fastener of FIG. 8 is generally designated 70 and comprises an upper or male fastener, generally designated 72, which comprises a head (not shown), which may be identical to head 30 of FIG. 1, and an extended shaft 28. The distal end 74 is threadless but comprises a diametrally enlarged male connector 76, for purposes yet to be explained.

Two-part fastener assembly 70 also comprises a lower or female fastener member 78, shown as being identical to fastener member 24, FIG. 1, except threads 38 have been eliminated and a female annular grove 80 added in lieu thereof. The boss portion 36 also is without an outside indentation. The male annulus 76 and female groove 80 are sized and shaped such that when the top fastener 72 is driven, with a sledge hammer or like instrument, the annulus 76 forcibly passes through the hollow of the boss 36 and come to rest in the groove 80. Thus, the two fasteners 72 and 78 become locked to prevent inadvertent separation notwithstanding the vibration caused by railroad trains moving along the railroad track.

Reference is now made to FIG. 9, which illustrates a further two-part fastener embodiment in accordance with the principles of the present invention, generally designated 90. Fastener assembly 90 comprises a top fastener member, generally designated 92, and a bottom fastener member, generally designated 94. Fastener member 92 comprises a head (not shown) similar to previously described head 30 and a shank or shaft 28 running the full length of the fastener 92 without external threads. At the lower blunt edge 96 it is found a threaded blind bore 98, the diameter of which is reduced, at location 40, to create an anti-rotate binding site.

Fastener 94 comprises previously described eccentric base 42, shown as being formed as one piece or integrated with a threaded upright stud 99 such that the axis of the stud 99 is eccentric to the axis of the base 42 to prevent rotation of the fastener member 94, while in a tie aperture, when the threads at 98 are turned into or out of the threads of bore 98. The engagement of detent 40 with the threads of stud 98 prevents inadvertent separation of fastener members 92 and 94 because fastener member 92 is constrained at 40 against rotation.

Reference is now made to FIG. 10, which illustrates, in diagrammatic form, one way in which pre-plated ties may be manufactured and stored in inventory or transported on vehicles for use. FIG. 10 is particularly significant in regard to the utilization of hard wood ties for which the present invention has particular application. In short, logs 100 are cut from trees 102 and thereafter, using commercial techniques, ties 44 are cut to size from logs 100. Ties 44 are pre-formed with a patterned array of apertures 50 located so as to become aligned with apertures into tie plates 46 placed on the top surface 45 of each tie 44.

A top fastener member of any of the types described above is placed, from the top, through each tie plate apertures 47 so as to extend into the associated tie aperture. A lower fastener member of the invention is placed from the bottom non-rotatably in the lower part of the associated tie aperture. The upper fastener member is connected against inadvertent separation to the lower fastener member, the connection being within the associated tie apertures 50, as explained above to create spikeless pre-plated ties, which may be stacked in inventory, as indicated at site 104, or placed on a vehicle and transported elsewhere for inventory or use purposes, as illustrated at site 106 in FIG. 10.

The invention may be embodied in other specific forms without departing from the spirit of the essential characteristics thereof. The present embodiments, therefore, are to be considered in all respects as illustrative and are not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. 

1. A pre-plated railroad tie assembly comprising: a railroad tie comprising a top surface and a bottom surface, the tie having a plurality of apertures extending between the top and bottom surfaces of the tie; at least one tie plate contiguous with the top surface of the tie, the tie plate defining apertures aligned and size compatible with the tie apertures; a two part fastener disposed in each set of aligned tie and tie plate apertures, one fastener comprising threadedly connected first and second members; each first fastener member comprising a head disposed above and tightly contiguous with the tie plate and a depending shaft extending through one tie plate aperture and into the aligned tie aperture, the shaft comprising threads at at least the lower end thereof; each second fastener member comprising a threaded boss disposed in the associated tie aperture and an anti-rotate base disposed below the boss.
 2. A pre-plated tie assembly according to claim 1 wherein the at least one tie plate comprises two spaced tie plates.
 3. A pre-plated tie assembly according to claim 1 wherein the threaded connection between the first and second fastener members comprises an anti-rotate connection which alleviates inadvertent loosening of the fastener members.
 4. A pre-plated tie assembly according to claim 3 wherein the anti-rotate connection comprises a change in diametral size in the threads of at least one of the fastener members which binds the threads of the fastener members against inadvertent loosening.
 5. A pre-plated tie assembly according to claim 1 wherein at least some of the first fastener member comprise a lower end disposed within the associated tie aperture.
 6. A pre-plated tie assembly according to claim 1 wherein at least some of the second fastener members are entirely disposed within the associated tie aperture.
 7. A pre-plated tie assembly according to claim 1 further comprising a protective covering disposed below at least some of the bases to alleviate deterioration.
 8. A pre-plated tie assembly according to claim 1 wherein the boss and anti-rotate base of at least some of the second fasteners are of one piece construction.
 9. A pre-plated tie assembly according to claim 1 wherein at least some of the bosses are crimped to create an anti-rotate site to prevent inadvertent loosening at the threaded connection.
 10. A pre-plated tie assembly according to claim 1 wherein the tie is selected from the group consisting of wood, synthetic resinous material and composite material.
 11. A pre-plated tie assembly according to claim 1 wherein at least some of the anti-rotate bases are eccentric in respect to the associated boss.
 12. A pre-plated tie assembly according to claim 11 wherein at least some of the anti-rotate bases are disposed in a recess of the tie aperture eccentric to the shaft.
 13. A method of pre-plating a railroad tie comprising the acts of: providing a railroad tie comprising a top surface and a bottom surface; creating a plurality of apertures arranged in a pattern in the tie between the top and bottom surfaces; placing two tie plates, each having a pattern of active apertures, on the top surface of the tie so that each active tie plate aperture is aligned with a tie aperture; lowering a shaft fastener, comprising a proximal head and distal threads, through each active tie plate aperture and into the associated aligned tie aperture; placing an anti-rotate fastener comprising threads in a lower portion of each tie aperture; threading the two sets of threads together until the head is tight against the associated tie plate.
 14. A method according to claim 13 wherein the threading act comprises relatively of rotating the threads of one fastener through a binding site in the threads of the other fastener.
 15. A method according to claim 13 comprising the further act of confining the location of each fastener to a location entirely within the associated tie aperture.
 16. A method according to claim 13 comprising the further act of creating an anti-rotate relation between each anti-rotate fastener and the associated tie aperture.
 17. A fastener assembly by which an apertured tie plate is secured contiguous with a top surface of an apertured railroad tie comprising: a shaft fastener member, for placement in aligned tie plate and tie apertures comprising an enlarged proximal head to be tightened against the tie plate, a central shaft and distal threads; an anti-rotate fastener member, for placement in the tie aperture, comprising a threaded boss whereby the threads of one fastener member are relatively rotated into threaded relation with the threads of the other fastener member.
 18. A railroad comprising two spaced railroad rails: a plurality of spaced apertured railroad ties supporting the rails; each tie comprising a top surface, a bottom surface and an array of stepped apertures spanning between the top and bottom surfaces of the tie; two spaced apertured tie plates contiguous with the top surface upon which the respective railroad rails are supported, at least some of the apertures of the tie plates comprising a pattern corresponding to and aligned with the array of tie apertures; a two-part fastener disposed in at least some of the aligned tie and tie plate apertures; one fastener part comprising a fastener element comprising a proximal tie plate engaging head and distal threads; the other fastener part comprising a fastener element comprising threads threadedly connected to the distal threads and an anti-rotate element.
 19. A pre-plated railroad tie assembly comprising: a railroad tie comprising a top surface and a bottom surface, the tie having a plurality of apertures arranged in a pattern, each tie aperture arranged in a pattern, each tie aperture extending between the top and bottom surfaces of the tie; at least one tie plate contiguous with the top surface of the tie, the tie plate defining apertures in a pattern aligned and size compatible with the tie apertures; a two-part fastener disposed in each tie plate aperture; each first part fastener comprising a proximal head disposed above and contiguous with the tie plate and a depending shaft passing through an associated tie plate aperture and a first connector element at a distal end portion of the shaft; each second part fastener comprising a second connector element and an anti-rotate base disposed below the second connector element within the tie aperture.
 20. A pre-plated railroad tie assembly according to claim 19 wherein the first and second connector elements comprise interlocking structure selected from the groups consisting of threaded unions and force fit unions. 